Electric control system for directcurrent motors



R. L. KLAR, JR

July 25, 1950 ELECTRIC comm. svsm FOR DIRECT CURRENT MOTORS Filed Jan. 19, 1949 2 Sheets-Sheet 1 Fig.2.

INVENTOR Robert L. Klcr,J BY M8- ATTORNEY mm a 3 3 5 3 3 M 3 k .TLIL. M u t" m? I I l 8 4 I 2 L n as a a 2 j 9 2 a r 4 it I. 2 11 B 4 7 m. 7 4 5 4 R 4 5 C R. 5 v d: B K m v E m x I y- 5, 1950 R. KLAR, JR 2,516,577

ELECTRIC CONTROL SYSTEM FOR DIRECT CURRENT MOTORS Filed Jan. 19, 1949 2 Sheets-Sheet 2 WITNESSES: INVENTOR M Roger: L. Klur,Jr. 72w. Zfw W ATTORN EY Fig.3.

enema July 1950' ELECTRIC CONTROL SYSTEM CURRENT MOTOR Cincinnati, Ohio, assignor to Robert L. Klar, Jr.,

FOR DIRECT- S Westinghouse Electric Corporation, East Pittsburgh, Pa", a corporation of Pennsylvania Application January 19, 1949, Serial No. 71,596

10 Claims.

My invention relates to electric control systems, and more particularly to variable voltage systems utilized for reciprocating machine tools as planers.

In known variable voltage systems, the main generator for providing the output voltage has its field winding excited under control by a regulating generator. As a rule, the regulating generator is equipped with at least three field windings. One of these windings is self-exciting while the two others receive separate excitation. A pattern voltage of selected magnitude is applied to one of the latter windings, and the other is excited in dependence upon the voltage of the main generator and acts in opposition to the pattern field winding. When the output voltage of the system is in accordance with the selected value of the pattern voltage, the two separately excited field windings of the regulating generator balance each other so that their resultant control effect is zero. If the output voltage is higher or lower than the pattern voltage, the diiferential eifect of the two separately excited field windings in the regulating generator assumes a finite value and of such a direction as to cause the regulating generator to change the field excitation of the main generator by an amount and in such a direction as is required to reduce the departure of the output voltage from the desired value. In this manner, the system tends to maintain the main generator output voltage at a constant value determined by the selected magnitude of the pattern voltage. Such systems have been used for energizing and regulating the speed of a direct-current motor.

It is an object of my invention to achieve a self-regulating performance related in type to the one just mentioned, but by means of simpler control systems than those required in the known systems. In particular, the invention aims at achieving a self-regulating performance of high stability and reliability with the aid of a regulating generator in which a single field winding performs the functions of the above-mentioned three field windings heretofore customary.

Another object of my invention is the provision of a variable voltage drive especially suitable for machine tools which permits a frequent reversal of the drive motor and which secures a high reversing speed so that the drive can be used to advantage in conjunction with planers and other machines requiring very frequent reversals and operating often with relatively short strokes.

These and other objects, as well as the means provided by the invention for achieving them. a

2 will be apparent from the following description of the embodiment illustrated in the drawing, in which:

Figure 1 shows schematically a planing machine equipped with an electric drive motor, Fig. 2 a diagram of the electric system for controlling the drive motor, while Figs. 3 and 4 represent schematically two difierent circuits that occur during respectively different operating conditions of the control system shown in Fig. 2.

The planer illustrated in Fig. 1 has a supporting frame structure I which carries a horizontally reciprocable bed 2 for accommodating a work piece 3. The appertaining tool carrier is denoted by 4. Two adjustable dogs 5 and 6 are mounted on bed 2 for cooperation with a cut limit switch I and a return limit switch 8 which form part of the electric system for controlling the drive motor M of the machine tool.

The connection of motor M and limit switches l and 8 within the electric system is apparent from Fig. 2, where these elements are denoted by the same reference characters as in Fig. 1.

According to Fig. 2,"the drive motor M has an armature 9 and a separately excited field winding it. The armature 9 is connected across the armature II of a main generator G, and hence energized by the output voltage of generator G. This output voltage is controlled by a main generator field winding II. The shaft iii of armature H is driven by an auxiliary motor [4 operating at substantially constant speed. Shaft 13 also carries the armature l5 of a regulating generator R which has two control field windings l6 and I1. Mounted on the shaft ii of the main generator G is also the armature [8 of an exciter E equipped with a series field winding l9 and a shunt field winding 20. When the system is in operation, the exciter E impresses a substantially constant direct-current voltage on mains X and Y. It should be understood that the exciter E serves merely as a convenient source of constant directcurrent voltage, and, if desired, may be replaced by an available direct-current line or other voltage source without affecting the performance of the system proper.

The field winding iii of motor M is connected across mains X and Y in series with an adjusting rheostat 2|, the setting of which normally remains unchanged during the operation of the system. Consequently, the speed of motor M is determined by the output voltage generated in armature H of main generator G which, in turn, depends on the excitation of field winding I2.

The system for controlling the excitation of field I2 includes resistors 22. a rheostat 24, with two sliders 25 and 26, and two auxiliary resistors 23 and 29. The resistor 22 is series connected with field windings l6 and i2 and with the armature l so as to form a loop circuit. By proper dimensioning of resistor 22, this loop circuit is so tuned that its resistance characteristic coincides approximately with the no-load magnetization characteristic of the regulating generator B. As a result, the voltage generated by armature I5 is sustained by the self-exciting effect of field winding It so that this voltage tends to maintain its value at any point along the straight portion of the magnetization characteristic. Hence, a field control efiect of relatively low intensity sufiices to change the regulating generator voltage by shifting it along the straight portion of the characteristic, and this control eflfect is superimposed on the loop circuit by the circuit connections described hereinafter.

The loop circuit, at the junction of armature l5 and field winding [2. is connected to one terminal, Pi, of the main generator G. This same loop circuit, at the junction of field winding 16 and resistor 22, is connected, through resister 23 and contacts tib' to the other terminal, P2, of the main generator G. Contacts 31b are back,

- polarities oi the two generators, R and G, are

or normally closed, contacts of the accelerating relay AR. During normal loading of the motor M and thus normal speed of operation, contacts 3") are closed and thus help maintain the circuit just traced.

The accelerating relay AR-has its contacts 31a and 31b controlled by two main coils 32 and 33 and two calibrating coils 34 and 35. Coils 32 and 33 furnish the main energization for the relay but act in opposition to either of coils 34 or 35 so. that the position of contacts 3m and 3ib change only when the differential efiect of coils 32 and 33 exceeds a given value whose magnitude depends on which one of the coils 34 and 35 is energized at the particular time in question. Coil 32 is, when contacts 31 of the control relay CR are closed, connected across the main generator armature ll, namely terminals Pi and P2, and hence measures the output voltage of the main. generator. Coil 33 is connected across all the resistor sections of rheostat 24 and hence responds to a selected but constant voltage equal to the constant exeiter voltage minus the pattern voltage developed across resistor 28.

A better understanding of my invention may be obtained from a study of typical operating cycles. To start the equipment, the auxiliary motor 13 is energized, and in consequence, the main generator G is brought up to full speed, the regulating generator R is brought up to full speed, and the exciter E is brought up to full speed.

The exciter E builds up to full voltage and thereafter keeps bus X at a given constant positive voltage with reference to the negative or grounded bus- Y. The regulating generator R and the main generator G do not build up to any voltage. The reason for this follows from some of the features of my system of control. The regulating generator R, in the absence of some pattern field, or pattern field eifeet, is unstable because the resistance value of the loop circuit including the armature l5, resistor 22, series field I3 and main generator field I2 is so chosen as to coincide with the straight portion of the no-load saturation curve. This regulating generator thus inherently fails to build up. Further, as seen from Fig. 3, it is apparent that the such that they tend to nullify each other. Since the terminals PI and P2 are thus at no voltage, I

the motor M does not operate.

Assuming the planer platen, or bed 2, is in the extreme forward position-the extreme left-hand position in Fig. 1then the return limit switch 8 is open. To start the main motor M to move the bed 2 in the cut direction, the attendant actuates push button 56. This operation establishes an energized circuit from bus X through the cut limit switch 1, the back contacts of the return push button 55, the make contacts of the cut push button '56, the stop switch 51, actuating coil 36 of'the controlrelay CR to the negative bus Y.

Operation ofthe control relay CR causes the closing of contacts 31, 40, M and 42.

Closure of contacts 0 establishes a circuit from bus X through the cut limit switch, return push button 55, contacts 40 of control relay CR, back contacts 41 of the relay RR for return movement, the actuating 'coil 49 of the'relay RC for out movement to bus Y. The coil 34 of the accelerating relay AB is connected in parallel to coil 49 and is thus also energized by the closure of contacts 4U.

The closure of contacts 4| has no effect at this time because operation of the cut relay RC upon energization of coil 49 opens the circuit for coil 35 of the accelerating relay AR and opens the circuit for the actuating coil 43 of the return relay RR. Further, these coils 43 and 35 cannot become energized because the return limit switch 8 is open for the starting position specified.

The closure of contacts 42 provides a holding circuit for'coil 3B of the control relay CR. This relay thus continues to hold its contacts 31, All, 4| and 42 closed after the equipment has once been started.

Closure of contacts 31 connects the coil 32 to the terminals Pi and P2. No immediate effect will be produced on coil 32 because there is substantially no voltage across the terminals Pi and P2 for the time under consideration.

Energization of coil 34 causes the operation of the accelerating relay AR and the consequent opening of contacts 322; and the closing of contacts 31a. The opening of contacts 333) prevents the direct interconnection of the buses X and Y, namely, the connection of the exciter E to the field windings l5 and 12, but the closing of contacts 3 I a establishes a circuit from bus K through contaets 50, field winding 1, excitation control resistor 29, contacts Ma and contacts to the bus Y. The resistor 29 may be adjustable.

The field winding i1, having relatively many ampere turns thus rapidly causes the voltage of the regulating generator to build up with the polarity indicated. The regulating generator armature is connected in the loop circuit comprising terminal Pi, main field winding 62 for the generator G, series field winding it for the regulating generator R, resistor 22, and armature 15 back to terminal PI. The generator field winding [2 is thus heavily excited and a considerable voltage appears across terminals Pi and P2. The result is that the motor M accelerates its load with dispatch.

Coils 34 and 35 are merely calibrating coils. Coil 34 is efiective for the out direction and coil 35 for the reverse, or return, direction. Thus, as soon as the acceleration of the load by motor M is complete, the voltage across terminals Pi and P2 is up to normal, or somewhat above due to the action of field H, the coil 32 acting diiierential to the net energization of coils l4 and It causes the accelerating relay to drop out, coil 33 being difierential to 34 but of lesser magnitude.

Under normal operating conditions, the diil'erential eifect of coils 32 and I3 in opposition to coil 34 (or 35) maintains the energization below the pick-up value of the armature for relay AR. The result is that the accelerating relay AR remains in the illustrated position most of the time. During starting, and primarily during every reversal, namely while the motor M is caused to be retarded and accelerated, the differential eflect of coils 32 and 33 becomes small enough to temporarily eiiect the pick-up oi the armature of relay AR and thus the closing of contacts tin. The field winding i1 is thus energized at each reversal to effect rapid reversal.

When the field i1 is energized, the regulating effect, discussed more in detail below, is not in operation. An instant after acceleration is complete, contacts Sla open to thus disconnect field I! and contacts 3ib close to establish the regular operating circuit for the out direction or the reverse direction, depending on which of the relays RR or RC is at the time in question energized.

Energization of coil 49 causes the closing contacts 50 and and the opening of contacts 52 and 53. The closure of contacts II and ii energizes the circuit shown in Fig. 3.

This circuit of Fig. 3 may be traced from bus 1: through contacts II and ii, the adjustable lead 28 on the rheostat 24, the resistor sections of the rheostat to the left of the connecting position of the conductor 26 (in Fig. 3 the resistor sections in question are at the right), series field it of the regulating generator R, the main field I: of the main generator G, the armature H of the main generator G, back contacts 3| b of the accelerating relay AR, and contacts 4! to the negative bus Y of the exciter E.

The coil ll of the accelerating relay is connected across the rheostat 24 and is thus also, as now indicated, inthe circuit discussed in the preceding paragraph. A resistor 22 and the armature ii of the regulating generator R are connected in a loop circuit as more clearly shown in Fig. 3. The motor M is connected directly to the terminals PI and P2 of the main generator (3- and the contacts 31 and coil 32 of the accelerating relay AR are also connected to the terminals PI and P2, respectively. Further, a resistor 28 is connected across the Junction between field I 6 and resistor 22 and the junction between contacts lib and contacts 40.

Once the motor M starts the push button 58 is released to the position shown. This does not affect the operation, since the holding circuit through contacts 42 is completed. Drop-out of control relay CR can thus be efi'ected only through actuation oi the stop switch 51.

It will be recognized from Fig. 3 and its comparison with the more detailed showing oi Fig. 2 that after the picking up 01' relays CR and R0, the portion of the regulating loop circuit that contains the series-connected field windings I2 and it is connected in a circuit-which includes in series the main generator mature and the exciter E with the appertainingrheostat 24. The polarity of connection is such that the variable voltage Ea generated in the armature II and impressed on the drive motor M is in series opposition to the constant voltage (pattern voltage) E9 appearing acm resistor II but derived from the exciter and adjusted by means oi the slider N on when the generator voltage Ea is equal to the adJusted pattern voltage Ep, the resultant voltage impressed on the loop circuit L, including armature ll, resistor 22 and fields I6 and I2, is zero. Consequently, the voltage then generated in armature it of generator R remains constant, thus exciting the main generator field II for maintenance oi the voltage Ea; and the motor M is caused to operate at a substantially constant speed whose value is in accordance with the setting of slider 2! on rheostat 24.

When the motor speed is below the desired value, and hence the generator output voltage Eg below the pattern voltage Ep, the resultant of both voltages has the direction voltage and is impressed on the loop circuit with the eilect of a separate and corrective excitation. This, in turn, causes the regulating generator to generate a correspondingly increased voltage in its armature II. This increased control voltage is eflective in the main generator field winding I2 to raise the generator output voltage Ea to the correct value, thereby increasing the speed of the drive motor correspondingly. When the generator voltage Ea and the speed of motor M are too high, a resultant of voltages Ep and Eq appears in a direction determined by that of voltage Eu. This resultant voltage imposes on the regulating loop circuit L a corrective excitation in the direction opposite to that above mentioned so that the armature I! is caused to reduce its generated voltage, thereby reducing the field excitation of generator G and the speed of motor M accordingly until the voltages Ep and E9 are again balanced.

It will be recognized that during the performance described in the foregoing only the field winding it of regulating generator R is in operation, and that this winding performs three functions, namely, the provision of self-excitation, a field response to a selected pattern voltage sup plied irom buses X and Y, and a response to a variable or pilot voltage supplied by generator G.

During the initial portions of the cutting stroke the dog 8 resets the return limit switch 8 (Fig. 1) to closed position and at or near the end or the cutting stroke the dog 5 (Fig. 1) opens the cut limit switch 1. The opening of the cut limit switch 1 effects the deenergization of coils 34 and 48.

The out control relay RC thus drops out opening the contacts II and ii, and closing the contacts l2 and 53. The closure of contacts 53 establishes a circuit i'rom bus X through the return limit switch 8, the cut push button 56, contacts 4i and 53, coil 43 01' the return control relay RR to bus Y. The calibrating coil 35 is connected in parallel with coil 43 and is thus also energized at the end of the return stroke.

Again accelerating relay AB is caused to close the contacts Ila and to open contacts tib. The energization oi coil 43 effects the closing of contacts 44 and 4!, and the opening 01' contacts 4| and 41. The opening of contacts 45 disconnects terminal P! from th bus Y. The opening of contacts 41 prevents any possibility oi energizing coil 4! when the limit switch 1, during the initial stages of the return stroke, is closed. The closure of contacts "and Ila establishes a circuit irom bus K through contacts 45 and tin, resistor ll, field winding il (energized in opposite direction to the energization in the cut direction) and back contacts 52 to the negative bus Y. The poiarityof both the regulating generator R and the main generator is reversed. The motor is stopped rapidly and accelerated in the reverse direction in view of the heavy excitation or field winding 11.

As soon as acceleration is completed, the accelerating relay drops out to close contacts all: and open contacts 3hr. This operation in conjunction with previous operation of the reverse, or

return, relay RR, having closed the contacts 65 and 45, establishes a circuit from the positivebus K through contacts 45 and 3th to terminal P2, armature ll of the main generator to terminal Pl, field windings l2 and E6 of the main generator and regulating generator R, respectively, the relatively few resistorsections of rheostat 24 to the right of the junction of the adjustable conductor 25, the conductor 25, and contacts 44 and 52 to the negative bus Y.

Since fewer resistor sections of the rheostat 24 are included in the circuit for the fields l2 and IS, the pattern field effect is greater than for the out direction, and as a result the motor M is operated in the return direction at a higher speed. The various loop circuits discussed in connection with the out direction are also associated with the circuit traced, but all the units are energized with opposite polarity. The return stroke is terminated when the dog 5 (Fig. l) causes the return limit switch 8 to open the circuit for coil 43. I

When the strokes of the driven machinery are relatively long, the reversing performance extends only over a small portion at thebeginning and end of each stroke. Whenthe operating strokes are reduced, the quick reversing performanw of the circuit extends over a correspondingly larger proportion of each stroke, and the system may be so adjusted that when the strokes are very small, the accelerating relay AR remains picked up virtually all of the time so that no regulating elicct is produced.

It will be understood by those skilled inthe art that the loop circuit feature according to Figs. 3 and 4 can be used without applying the quick reversing feature; and that for other special cases of application the quick reversing feature may be applied without using the circuit features of Figs. 3 and 4. It will further be understood that variable voltage systems according to the invention can be modified and altered with respect to detailsv of the control circuits and appertaining circuit devices without departing from the principles of the invention and within its essential features as set forth in the claims annexed hereto.

I claim as my invention:

1. A variab e voltage system, comprising a main generator having an armature for providing an output voltage and a field winding for controlling said voltage, a regulating generator having an armature and a field winding connected together with said main generator field winding to form a closed circuit, and energized circuit means, to provide a pattern voltage, connected in series with said main generator armature across said two field windings for causing said regulating generator to regu ate said main generator for maintaining said output voltage at a value determined by said pattern voltage.

2. A variable voltage system, comprising a main generator having an armature for providing an output voltage and a field winding for controlling said voltage, a regulating generator having an armature and a field winding connected together with said main generator field winding to form a closed circuit, said closed circuit having a resistance adjusted so that the resistance characteristlc coincides approximately with the no-load magnetization characteristic oi said regulating generator, and energized circuit means for providing a pattern voltage having rheostat means for adjusting said pattern voltage and being con= nected in series with said main generator armature across said two field windings for causing said regulatinggenerator to regulate said main generator for maintaining said output voltage at a value determined by said pattern voltage.

3. A variable voltage system, comprising a main generator having an armature for providing an output voltage and a field winding for controlling said voltage, a regulating generator having an armature and a field winding connected together with said main generator field winding to form a closed circuit, voltage supply circuit means, for

providing a pattern voltage, connected in series with said main generator armature across said two field windings for causing said regulating generator to regulate said main generator for maintaining said output voltage at a value determined by said pattern voltage, and reversing contact means forming part of said circuit means for reversing the polarity of said pattern voltage in order to cause said main generator to reverse said output voltage.

4. A motor control rect-current motor, a maingenerator having an armature connected to said motor for providing adjustable voltage therefor and a field winding for controlling said voltage, a regulating generator having an armature and a field winding connected together with said main generator field winding to form a closed circuit, and energized circuit means for providing 'a pattern voltage and connected in series with said main generator armature across said two field windings for causing said regulating generator to regulate said main generator for maintaining said motor at a speed determined by said pattern voltage.

5. A motor control system, comprising a direct-current motor, a main generator having an armature connected to said motor for providing adjustable voltage therefor and a field winding for controlling said voltage, a regulating generator having an armature and a field winding connected together with said' main generator field winding to form a closed circuit said closed circuit having a resistance adjusted so that the resistance characteristic coincides approximately with the no-load magnetization characteristic of said regulating generator, and voltage supply circuit means for providing a pattern voltage having rheostat means for adjusting said pattern voltage and being connected in series with said main generator armature across said two field windings for causing said regulating generator to regulatev said output voltage for maintaining said motor at a speed determined by said adjusted pattern voltage.

6. A motor control system, comprising a di-' rect-current motor, a main generator having an armatureconnected to said motor for. providing adjustable voltagethereicr anda field winding for controlling. said voltage, a regulating generator having an armature and a field winding connected in series with said main generator field winding to form a loop. circuit, voltage supply circuit means" disposedfor providing a pattern voltage and comprising an exciter and a rheostat connected in series with said main generator armature across said two field windings to regusystem, comprising a di- 

